PDF Troubleshooting Technical Manual Hitachi ZW550-6 Wheel Loader - 4 MB
Efficiently diagnose and resolve issues with your Hitachi ZW550-6 Wheel Loader using this specialized troubleshooting technical manual.
This guide provides systematic procedures, error code explanations, and diagnostic flowcharts to help technicians pinpoint problems quickly.
It's an invaluable asset for minimizing downtime and ensuring repairs are done correctly.
This manual is designed for trained service professionals to keep your equipment in peak condition.
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--- Page 1 ---
PART NO. TTNHK70-EN-00
ZW550-6
WHEEL LOADER
Technical Manual
Troubleshooting
TECHNICAL MANUAL TROUBLESHOOTING
ZW550-6
Wheel Loader
URL:http://www.hitachi-c-m.com
TTNHK70-EN-00
Service Manual consists of the following separate Part No.
Technical Manual (Operational Principle) : Vol. No.TONHK70-EN
Technical Manual (Troubleshooting) : Vol. No.TTNHK70-EN
PRINTED IN JAPAN (K) 2018, 07 Workshop Manual : Vol. No.WNHK70-EN
--- Page 3 ---
SAFETY
Recognize Safety Information
ο These are the SAFETY ALERT SYMBOLS.
ο When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
ο Follow recommended precautions and safe operating
practices.
SA-2644
Understand Signal Words
ο On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or CAUTION
- are used with the safety alert symbol.
ο DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
ο WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
ο CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
ο DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs.
ο Some safety signs do not use any of the designated signal
words above after the safety alert symbol has been used
on this machine.
ο CAUTION also calls attention to safety messages in this
manual.
ο To avoid confusing machine protection with personal
safety messages, a signal word IMPORTANT indicates a SA-1223
situation which, if not avoided, could result in damage to
the machine.
ο f NOTE indicates an additional explanation for an
element of information.
TTNHK70-EN-00 SA-1
--- Page 4 ---
SAFETY
Equipment of Head Guard, ROPS, FOPS
In case the machine is operated in areas where the possibility
of falling stones or debris exist, equip a head guard, ROPS, or
FOPS according to the potential hazardous conditions. (The
standard cab for this machine corresponds to ROPS and FOPS.)
Any modification of the ROPS structure will modify its
performances and its certification will be lost.
ROPS: Roll-Over Protective Structure
FOPS: Falling Object Protective Structure
SA-521
Provide Signals for Jobs Involving Multiple
Machines
ο For jobs involving multiple machines, provide signals
commonly known by all personnel involved. Also, appoint
a signal person to coordinate the job site. Make sure that all
personnel obey the signal personβs directions.
SA-481
TTNHK70-EN-00 SA-11
--- Page 5 ---
SAFETY
Park Machine Safely
To avoid accidents:
ο Park the machine on a firm, level surface.
ο Lower bucket to the ground.
ο Put the forward / reverse lever (switch) in neutral, and
turn the parking brake switch (lever) ON (parking brake)
position.
ο Run the engine at low idle speed without load for 3
minutes.
ο Turn key switch to OFF to stop engine.
ο Remove the key from the key switch.
SA-456
ο Turn the control lever lock switch to the lock ( ) position.
ο Close windows, roof vent, and cab door.
ο Lock all access doors and compartments.
Store Attachments Safely
ο Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
ο Securely store attachments and implements to prevent
falling. Keep children and bystanders away from storage
areas.
SA-034
TTNHK70-EN-00 SA-21
--- Page 6 ---
SAFETY
Beware of Exhaust Fumes
ο Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
ο If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.
ο PM (Particle Matter) combustion may generate white
smoke during aftertreatment device regeneration. Do
not attempt to perform aftertreatment device manual
regeneration in a badly ventilated indoors.
SA-016
Precautions for Welding and Grinding
ο Welding may generate gas and / or small fires.
ο Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe place
before starting welding.
ο Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
ο Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
ο After finishing welding and grinding, recheck that there are
no abnormalities such as the area surrounding the welded
area still smoldering. SA-818
Avoid Heating Near Pressurized Fluid Lines
ο Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to yourself
and bystanders.
ο Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
ο Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary
fire-resistant guards to protect hoses or other materials
before engaging in welding, soldering, etc.
SA-030
TTNHK70-EN-00 SA-31
--- Page 7 ---
SECTION AND GROUP SECTION 4 OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Machine Performance Test
TECHNICAL MANUAL Group 5 Component Test
Group 6 Adjustment
(Troubleshooting)
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor
Group 3 e-Service
Group 4 Component Layout
Group 5 Troubleshooting A
Group 6 Troubleshooting B
Group 7 Air Conditioner
All information, illustrations and
specifications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
COPYRIGHT(C)2018
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TTNHK70-EN-00
--- Page 8 ---
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
Performance Test Designation Unit Performance Remarks Reference
Standard Page
Control Lever Operating Force N (kgf ) (lbf ) MF (Joystick type) lever T4-4-14
Lift Arm Raise 20 (2.0) (4.5) or less
Lift Arm Raise (Detent) 40 (4.0) (9.0)or less
Lift Arm Raise (Detent Release) 50 (5.0) (11.2) or
less
Lift Arm Lower 20 (2.0) (4.5) or less
Lift Arm Lower (Float) 40 (4.0) (9.0) or less
Lift Arm Lower (Float Release) 50 (5.0) (11.2) or
less
Bucket Control Lever Roll Back 20 (2.0) (4.5) or less
Bucket Control Lever Roll Back 40 (4.0) (9.0) or less
(Detent)
Bucket Control Lever Roll Back 50 (5.0) (11.2) or
(Detent Release) less
Bucket Control Lever Dump 30 (3.0) (6.7) or less
Joystick Steering Lever 7.9 (0.8) (1.8) or
less
Accelerator Pedal 40Β±2 (4.0Β±0.2)
(9.0Β±0.4)
Brake Pedal (Right) 336+60/-40 (34.3+6.1/-
4.1) (75.5+13.5/-9.0)
Declutch Pedal (Left) 318+60/-40 (32.4+6.1/-
4.1) (71.5+13.5/-9.0)
fNOTE: MF: Multi-Function
TTNHK70-EN-00 T4-2-5
--- Page 9 ---
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
(Blank)
TTNHK70-EN-00 T4-4-3
--- Page 10 ---
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Bucket Levelness
Summary:
Check left and right inclinations of the bucket.
Preparation:
1. Place the unloaded machine on a level platen on
the ground. (In case a platen is not available, place
it on a horizontal flat concrete on the ground. Deal
with the measurement values as guide lines.)
2. Adjust the tire air pressure to the designated value 1
all evenly.
3. Lower the bucket onto the ground in the horizontal
position.
115T4GB-04-04-011
Measurement:
dCAUTION: Never put hands, feet, and measuring
instruments under the bucket.
1. Float the bucket bottom slightly above the platen.
2. Measure the vertical distance from the platen and
the bottom surface of space edge (1) on the left and
right ends, and confirm the difference.
3. Repeat the measurement three times and calculate
the mean values.
Evaluation:
Drift amount: 10 mm (0.4 in) or less
TTNHK70-EN-00 T4-4-13
--- Page 11 ---
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
Main Pump Delivery Pressure
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Remove the plug from pressure check port (1).
Install a pressure gauge with an adapter, hose, if 3
needed.
j : 19 mm
1
4. Start the engine. Confirm that no oil leakage is
2
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 55Β±5Β°C
(131Β±9Β°F).
115Z7-04-05-01
Measurement:
1. Set the following conditions: 1- Check Port (G1/4) 3- Pump Delivery Pressure
2- Main Pump Sensor
Accelerator Power Mode Parking Forward/
Pedal Switch Brake Switch Reverse
Switch
Full stroke ON ON N
2. Measure pressure with the control levers in neutral
without load.
3. Repeat the measurement three times and calculate
the mean value.
Evaluation:
Standard (neutral): 4.0+1.0/-0.5 MPa (580+145/-73 PSI)
Remedy:
Refer to Troubleshooting A for any accompanied error
code.
Refer to Troubleshooting B for observed phenomena.
fNOTE: All Actuator System Troubleshooting (p.T5-6-30)
Front Attachment System Troubleshooting (p.T5-6-33)
Steering System Troubleshooting (p.T5-6-37)
TTNHK70-EN-00 T4-5-7
--- Page 12 ---
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
Measurement:
1. Set the following conditions:
Accelerator Pedal Power Mode Switch
Full stroke ON
2. Measure the pressure when fully depressing the
brake pedal at left side to the floor.
3. Repeat the measurement three times and calculate
the mean values.
Evaluation:
Standard: 4.2Β±0.6 MPa (609Β±87 PSI)
Remedy:
Refer to Troubleshooting B.
Normally, the front and rear wheel brake pressures
become equal. If not, malfunction of the brake valve
and dirt caught in the valve are suspected.
f NOTE: Brake System Troubleshooting (p.T5-6-42)
TTNHK70-EN-00 T4-5-17
--- Page 13 ---
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
Clutch Pressure Measurement Port
Main clutch pressure test port
A
A
Each clutch pressure test port
Transmission Valve Assy Side View A-A
Lock-up clutch pressure
test port (PF1/4)
Torque Converter Top View 115Z7BT04-05-05
Transmission Clutch Pack Combination
Directional Control Clutch Pack Speed Control Clutch Pack
Selected Speed Forward Low Forward High Reverse (R) First Speed (1) Second Speed Third Speed Lock Up (LU)
Shift (L) (H) (2) (3)
F1 ο ο
F2 ο ο
F2L ο ο ο
F3 ο ο
F3L ο ο ο
F4 ο ο
F4L ο ο ο
R1 ο ο
R2 ο ο
R2L ο ο ο
R3 ο ο
R3L ο ο ο
Neutral * * *
fNOTE:
ο In the neutral position, either clutch with an asterisk (*) is engaged.
ο The operating pressure is applied to the clutch with the mark ο when setting
the forward/reverse lever and the shift switch to each selected speed shift.
TTNHK70-EN-00 T4-5-27
--- Page 14 ---
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
5. Perform troubleshooting
dCAUTION: Do not disconnect harnesses or
hydraulic lines while the engine is running. The
machine may malfunction or pressurized oil may
spout, possibly resulting in personal injury. Stop
the engine before disconnecting harnesses or
hydraulic lines.
Perform diagnosis by connecting MPDr. to the machine
or by using the service menu of monitor.
In case any fault code has been displayed by diagnosis
by using MPDr. (the service menu of monitor),
check the cause of the trouble by referring to
Troubleshooting A in this section. In case any fault
code has been displayed by diagnosis by using MPDr.
(the service menu of monitor), write the fault code.
TNED-05-01-001
Delete the fault code once and retry self-diagnosis
again. If the fault code is displayed again, check the
cause of the trouble by referring to Troubleshooting
A in this section. After the machine trouble has been
corrected, the fault code (displayed by the service
menu of monitor) will be deleted. Therefore, in case
the problems which are not easily re-predicable are
encountered, check the fault code by using MPDr.
In case the fault code is not displayed, check operating
condition of each component by referring to
Troubleshooting B in this section and by using MPDr.
(the service menu of monitor).
fNOTE: Note that the fault codes displayed do not
necessarily indicate machine trouble. The controller
stores even temporary electrical malfunctions, such as
a drop in battery output voltage or disconnection of the
switches, sensors, etc., for inspections. For this reason,
the "RETRIAL" is required to erase the accumulated fault
codes from the controller memory and to confirm if any
fault codes are indicated after the "RETRIAL".
TTNHK70-EN-00 T5-1-3
--- Page 15 ---
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Battery Voltage Check
1. Turn the key switch OFF. Check voltage between the
battery positive terminal and the body (ground).
Normal Voltage: 24 V
fNOTE: If voltage is abnormal, recharge or replace the
battery.
2. Start the engine. Check voltage between the
battery positive terminal and the body (ground).
Normal Voltage: 26 to 28 V
fNOTE: If voltage is abnormal, check the charging Machine Front
system.
115Z7BT05-01-01
TTNHK70-EN-00 T5-1-13
--- Page 16 ---
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Check by False Signal
Two Polarities
Turn the key switch OFF. Disconnect the sensor connector.
1 2
Turn the key switch ON. Connect terminal #1 (power
source) of the body harness end connector to terminal #2
(signal). (Power voltage is used as a false signal.)
Check this state by using the monitor function of MPDr.
When the maximum value is displayed, MC and the circuit
up to the body harness end connector are normal. If "ON"
is displayed, the pressure switch circuits are normal.
IMPORTANT: Do not connect terminal #1 or #2 T107-07-05-010
to terminal #3 or to the body (ground) when
checking a three-polarity connector.
Three Polarities
1 2 3
fNOTE: Some kinds of sensors can be monitored by the
service menu of the monitor.
T107-07-05-011
TTNHK70-EN-00 T5-1-23
--- Page 17 ---
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
8. The selected monitoring item is started monitoring.
fNOTE: Actual Engine Speed and Actual Vehicle Speed are
selected as an example here.
95TNED-05-02-19
1 2
9. When pushing select / confirm knob (3) while
monitoring, PAUSE (8) is displayed and the monitoring
value can pause (be held).
10. When pushing select / confirm knob (3) again, pausing 3
is stopped.
TNED-05-02-002
fNOTE: Even if the key switch is set to OFF position, the 8
selected monitoring item has been stored. In order to
release the selected monitoring item, select CLEAR (7) on
the Monitoring screen and push select / confirm knob (3) for
a while until START (6) and CLEAR (7) disappear.
11. When pushing return to previous screen switch (1), the
previous screen appears.
12. When pushing return to basic screen switch (2), the
95TNED-05-02-18
basic screen appears.
6
7
95TNED-05-02-17
TTNHK70-EN-00 T5-2-7
--- Page 18 ---
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Issued Warning Record 1 2
1. Turn select / confirm knob (3) and select Issued
Warning Record (4) on Service Menu.
3
TNED-05-02-002
4
2. When pushing select / confirm knob (3), the Issued
95TNED-05-02-10
Warning Record screen appears.
The symbol and trouble of maximum ten alarms which
occurred and reported recently are displayed. (Refer To
List of Alarm.)
3. Turn select / confirm knob (3) and select the displayed
95Z7B-05-02-21E
alarm. When pushing select / confirm knob (3), the
time (ON / OFF) when the selected alarm has occurred
/ solved are displayed.
4. In case of currently occurring alarms, the resolving
95Z7B-05-02-22E
time (OFF) of the alarm is dashed (---).
fNOTE: The display of date and time depends on the
setting. (Refer to the operatorβs manual.)
5. When pushing return to previous screen switch (1), the 95Z7B-05-02-23E
previous screen appears.
6. When pushing return to basic screen switch (2), the
basic screen appears.
TTNHK70-EN-00 T5-2-17
--- Page 19 ---
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Monitor Operation:
1 2
IMPORTANT: Do not operate control levers and other
switches when learning is performed.
1. Turn select / confirm knob (3) and select Machine 3
Setting (4) on Service Menu.
TNED-05-02-002
4
95Z7B-05-02-11E
2. When pushing select / confirm knob (3), the Machine 5
Setting screen appears.
3. Turn select / confirm knob (3) and select Transmission
Learning (5).
95TNED-05-02-61
TTNHK70-EN-00 T5-2-27
--- Page 20 ---
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Aftertreatment Device No.
1 2
1. Turn select / confirm knob (3) and select
Aftertreatment Device No. (4) on Service Menu.
3
TNED-05-02-002
4
95Z7B-05-02-11E
2. When pushing select / confirm knob (3), the
Aftertreatment Device screen appears.
3. The manufacturing number (S/N) of aftertreatment
device (DOC, SCR) is displayed.
95Z7BTT05-02-05E
4. When pushing return to previous screen switch (1), the
previous screen appears.
5. When pushing return to basic screen switch (2), the
basic screen appears.
TTNHK70-EN-00 T5-2-37
--- Page 21 ---
SECTION 5 TROUBLESHOOTING
Group 3 e-Service
List of Total Operating Hours
Item Details
Hour Meter End Hour meterβs value accumulated in machineβs monitor
Travel Distance Odometerβs value accumulated in machineβs monitor
Engine Power Mode OFF and Total engine operating hours selecting power mode (OFF) and TCS (OFF)
Operating TCS OFF Hours
Hours Power Mode ON and Total engine operating hours selecting power mode (ON) and TCS (OFF)
TCS OFF Hours
Power Mode OFF and Total engine operating hours selecting power mode (OFF) and TCS (ON)
TCS ON Hours
Power Mode ON and Total engine operating hours selecting power mode (ON) and TCS (ON)
TCS ON Hours
Consumed Fuel Quantity Total amount of fuel usage amount
Idling Hours Total operating hours when setting forward/reverse lever and forward/reverse
switch (OPT) in (N) position and running engine at less than 950 min-1
TTNHK70-EN-00 T5-3-5
--- Page 22 ---
SECTION 5 TROUBLESHOOTING
Group 4 Component Layout
Controller and Relays
5
1
3
4
35 2
36
33
11 10 9 8 7
16 15 14 13 12
32
21 20 19 18 17
26 25 24 23 22
31 30 29 28 27
34
6
ZW550-6UT01-02-03
1- Monitor Controller 13- Work Light Relay (Rear) 25- Wiper Relay (Rear)
2- Flasher Relay 14- Right Turn Signal Light Relay 26- Washer Relay (Rear)
3- Air Conditioner Controller 15- Horn Relay 27- Starter Cut Relay
4- MC (Main Controller) (Main) 16- - 28- Engine ECM Main Relay
5- MC (Main Controller) (Sub) 17- Parking Brake Relay 1 29- Secondary Steering Relay (Option)
6- ECM (Engine Control Module) 18- Parking Brake Relay 2 30- Cab Working Light Relay (Rear)
7- Head Light Relay (Left) 19- Loading Control Lever Lock Relay 31- Cab Working Light Relay (Front) (Option)
8- Head Light Relay (Right) 20- Brake Light Relay 32- Fuse Box
9- High-Beam Relay 21- Load Dump Relay 33- MPDr. Connector
10- Bucket Leveler Relay 22- Neutral Relay 34- Tech2 (Engine Diagnostic Tool) Connector
11- Back Lamp and Alarm Relay 23- Turn Signal Light Relay (Left) 35- Wiper Relay (Front) (HI)
12- Work Light Relay (Front) 24- Washer Relay (Front) 36- Wiper Relay (Front) (LO)
TTNHK70-EN-00 T5-4-7
--- Page 23 ---
SECTION 5 TROUBLESHOOTING
Group 4 Component Layout
Aftertreatment Device
7
B 6
3
C 8
From engine
5
B
2
A
C
A-A 4
1
A
B-B C-C
115Z7BT01-02-14
1- Diesel Oxidation Catalyst (DOC) Unit 4- DOC Outlet NOx Sensor 8- SCR Outlet NOx Sensor
2- DOC Inlet Exhaust Gas Temperature 5- Diesel Exhaust Fluid (DEF) Dosing Unit
Sensor 6- Selective Catalytic Reduction (SCR) Unit
3- DOC Center Exhaust Gas Temperature 7- SCR Inlet Exhaust Gas Temperature
Sensor Sensor
TTNHK70-EN-00 T5-4-17
--- Page 24 ---
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
MPDr. Fault Code List
Fault Code MPDr. Message Category Reference 1 Reference 2
111000-2 Abnormal EEPROM MC, SC T5-5-12, T5-5-26 T5-5-80
111001-2 Abnormal RAM MC, SC T5-5-12, T5-5-26 T5-5-80
111002-2 Abnormal A/D Converter MC, SC T5-5-12, T5-5-26 T5-5-80
111003-3 Abnormal Sensor Voltage MC, SC T5-5-12, T5-5-26 T5-5-80
111006-2 (MC) Engine Controller Communication Error MC T5-5-13 T5-5-83
111007-2 (MC) Information Controller Communication Error 1 MC T5-5-13 T5-5-83
111008-2 (MC) Information Controller Communication Error 2 MC T5-5-13 T5-5-88
111009-2 (MC) Monitor Controller Communication Error 1 MC T5-5-13 T5-5-83
111010-2 (MC) Monitor Controller Communication Error 2 MC T5-5-13 T5-5-88